Finlike structures and methods of making same

ABSTRACT

Semiconductor materials, particularly III-V materials used to form, e.g., a finlike structure can suffer structural damage during chemical mechanical polishing steps. This damage can be reduced or eliminated by oxidizing the damaged surface of the material and then etching away the oxidized material. The etching step can be accomplished simultaneously with a step of etching back a patterned oxide layers, such as a shallow trench isolation layer.

PRIORITY CLAIM AND CROSS-REFERENCE

This application is a continuation in part of U.S. patent application Ser. No. 14/030,518, entitled “Finlike Structures and Methods of Making Same,” filed on Sep. 18, 2013, which is a divisional of U.S. patent application Ser. No. 13/269,107, entitled “Finlike Structures and Methods of Making Same,” filed on Oct. 7, 2011, all of which are incorporated herein by reference.

BACKGROUND

Fin structures are becoming increasingly popular in forming advanced, small geometry semiconductor devices. One such structure is the so-called Fin-FET device wherein a device such as a metal oxide semiconductor (MOS) transistor or a bipolar junction transistor (BJT) is formed at least partially within a thin fin formed of a single crystal semiconductor material. While it is desirable to have a defect free fin for optimum device performance, various processing steps can induce damage to the crystal structure of the fin.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying figures. It is noted that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

FIGS. 1 a through 1 h are cross sectional views of intermediate steps in the manufacture of a first embodiment device.

FIGS. 2 a through 2 e are cross sectional views of intermediate steps in the manufacture of a second embodiment device.

FIG. 3 illustrates an illustrative FinFET device manufactured as an embodiment of the present invention.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

Various steps in the formation of a fin device will be described with reference to FIGS. 1 through 3. It should be appreciated that the materials, geometries, dimensions, structures, and process parameters described herein are exemplary only and are not intended to be, and should not be construed to be, limiting to the invention claimed herein. Many alternatives and modifications will be apparent to those skilled in the art, once informed by the present disclosure.

FIG. 1 a illustrates a semiconductor substrate 2 that may be employed in embodiments of the present disclosure. Substrate 2 may be bulk substrate, such as a bulk silicon wafer commonly employed in CMOS manufacturing processes. Alternatively, substrate 2 may be a compound substrate, such as a silicon-on-insulator (SOI) substrate, or another bulk or compound semiconductor substrate formed of other materials such as germanium, gallium-arsenide, III-V materials, and the like. Only a portion of substrate 2 is illustrated in the figures, as this is sufficient to fully describe the illustrative embodiments.

Recesses 4 are etched into substrate 2, as shown in FIG. 1 b using, e.g., a dry etch process employing an O₂, Argon, a chloro-fluoro-carbon (CFC) such as CF₄, or like material as an etchant in a plasma etching process. The details of such dry etch processes are well known in the art and hence are not repeated herein.

An oxide 6 is next formed over substrate 2 and filling recesses 4, as illustrated in FIG. 1 c. Oxide layer 6 is also referred to as shallow trench isolation (STI) in some applications, also known as a gap fill oxide in some applications. Oxide 6 may be deposited using chemical vapor deposition (CVD) techniques. In other embodiments, oxide 6 may be a spin on glass (SOG) oxide that is spun onto the surface, or some other alternatively deposited oxide. As shown, oxide 6 is deposited to a thickness that overfills recesses 4.

A chemical mechanical polish (CMP) step may next be employed to planarize the top surface of oxide 6 to the top of recesses 4, as illustrated in FIG. 1 d. The details of the oxide CMP step are known in the art and hence are not repeated herein. As shown in FIG. 1 d, after the CMP step, oxide regions 7 remain filling recesses 4 but no longer overfill the recesses.

The device illustrated in FIG. 1 d is then subjected to a silicon etch process, such as a wet etch using dilute hydro-fluoric acid (HF). In some embodiments, the dilute HF could be about a 1% solution of HF in water. Other silicon etch processes are within the contemplated scope, as well. The structure resulting after the silicon etch process is illustrated in FIG. 1 e. The portions of substrate 2 between oxide regions 7 has been etched away, leaving only oxide regions 7 that had previously filled recesses 4 and underlying substrate 2. Substrate 2 may be etched away slightly during the silicon etch process, but not appreciably relative to the thickness of substrate 2.

In a next process step, a fin material 8 is epitaxially grown on substrate 2 and around the oxide regions 7. One skilled in the art will recognize that although oxide regions 7 are shown as patterned into columnar shapes (and described as columnar herein), the illustrations are merely cross sectional views of the actual structure and the actual structure is elongated into and out of the plane of the page.

The result of this process is best illustrated in FIG. 1 f. Fin material 8 may comprise Ge, SiGe, GaAs, InP, or InGaAs, as just examples. Numerous other fin materials, including other III-V material or II-VI materials suitable for integrated circuit processing, including those currently recognized and those identified in the future, are considered within the contemplated scope of the present invention. Fin material 8 may be epitaxially grown using an metal organic chemical vapor deposition (MOCVD) process, as an example. Other epitaxial growth/deposition techniques could likewise be employed. In some embodiments, fin material 8 is in situ doped with, e.g., phosphorous, antimony, arsenic, carbon, and the like, during the epitaxial growth process. As illustrated fin material 8 is grown to fill and overfill the trenches between columnar oxide 6 features.

In a subsequent processing step, fin material 8 is subject to a CMP process to planarize the top surface of fin material 8 to be planar with the tops of oxide regions 7. In one illustrative embodiment, the CMP process involves, for instance, a slurry composition of about 5% to about 20% SiO₂, less than about 5% NH₄O₄, and greater than about H₂O₂>70%, at a slurry flow rate of from about 50 sccm to about 1,000 sccm. The CMP process may be performed at about room temperatures, say about 23° C. to about 25° C. for a period of time sufficient to provide the desired planarity, perhaps about 5 seconds to about 300 seconds. As illustrated in FIG. 1 g, fin material 8 is patterned by the CMP process into a series of fin shaped elements 10. These elements may be referred to herein as fins. The top surfaces of respective fins 10 may be damaged by the CMP process. This is schematically illustrated in FIG. 1 g, by the damaged regions 12. Damaged regions can be caused by several factors. One such factor is damage to the surface of fins 10 caused by the mechanical abrasion of the CMP pad. Additionally, abrasives in the CMP slurry may cause micro-scratches on the exposed surfaces of fins 10. Structural damage can also be caused by the chemical interaction of the fin material with the CMP slurry.

The above described structural damage to a fin 10 can adversely impact the performance of a device that is manufactured using the fin 10. For instance, dislocations in the crystal structure of fin 10 can provide a path for impurity migration, can increase leakage current, can affect threshold voltage, etc. In some instances, gate leakage could increase by 0.01 A/cm2 to 100 A/cm2, and threshold voltage could increase by 10 mV to 1,000 mV from the structural damage.

FIG. 1 h illustrates the results of an etch back process wherein oxide regions 6 are recessed back from the top surfaces of fins 10. The present inventors have discovered an etch back methodology that not only recesses oxide regions 7 to a desired level, but also provides additional advantages. One such advantage is that the top surface of oxide regions 7, after the etch back process, may be substantially more flat and planar relative to oxide regions that are etched back using conventional wet etch processes. Another advantage is that the etch back process described herein will simultaneously remove the damaged regions 12 of fins 10, leaving the resulting fins substantially free from the performance degrading defects and damage schematically illustrated in FIG. 1 g as damaged regions 12. The etch back methodology involves oxidizing exposed portions of fins 10 and then removing those oxidized portions while etching back the top surface of oxide regions 7.

In an illustrative embodiment, the etch back process proceeds as follows. In a first step of the process, the device is subject to an oxidizing treatment. In one specific embodiment, the oxidizing treatment comprises ozonated distilled water wherein the ozone concentration is from about 10 ppm to about 500 ppm. While the treatment may be performed at an elevated temperature, an advantageous feature of the illustrative embodiment is that the treatment may be performed at room temperature, thus preserving thermal budget. In an illustrative embodiment, the ozonated water treatment is performed for perhaps 30 to 120 seconds. It is believed that the top surface of fins 10, including damaged regions 12, are at least partially oxygenated during the ozonated water treatment. As but one example, assuming fins 10 are initially formed of GaAs, after treatment, the exposed surface of fins 10 is converted to an oxide of gallium arsenide, such as GaAsO down to a depth of about 5 Å to about 100 Å.

One advantageous feature of the oxidizing treatment is that the ozonated water (in an illustrative example, the water is ozonated from about 5 ppm to about 1,000 ppm) provides a cleaning treatment to exposed surfaces in addition to the oxidizing treatment. In some embodiments, however, other solutions may be employed for the oxidizing treatment. For instance, in some embodiments, H₂O₂ may be employed in addition to or in lieu of ozonated water for the oxidizing treatment. As one specific example, the oxidizing treatment comprises H₂O₂ at a concentration of about 1% to about 31%, a flow rate of from about 50 sccm to about 2,000 sccm, and a temperature of from about 23° C. to about 40° C. Other processes will be apparent to those skilled in the art using routine experimentation, once informed by the present teaching.

In a next step of the process, the device is subject to an etch. In an illustrative embodiment, the etch is a dry, plasma free etch process using, for example, a mixture of NH₄F and HF at a concentration of from about 0.005% to about 1% and a flow rate of from about 50 sccm to about 2,000 sccm. In this illustrative embodiment, the etch process is performed at a temperature in the range of 350° C. for a period of from about 30 to about 300 seconds. This etch process removes top surfaces of oxide regions 7 and hence etches back oxide regions 7 into recesses formed between fins 10. At the same time, this etch process removes portions of fins 10 that have been oxidized during the ozonated water treatment. While performing a plasma etch is a possible alternative, it should be noted that a plasma etch and/or bombardment treatment could further damage the exposed surfaces of fins 10, leading to less than ideal results. One skilled in the art will recognize that other etchants could be employed in addition to or in lieu of the above described NH₄F/HF mixture.

In some embodiments, a single cycle of ozonated water treatment and etch may be sufficient to etch back oxide regions 7 to a desired height and to remove damaged regions 12. In other embodiments, however, it may be desirable to subject the device to a series of cycles involving ozonated water treatment followed by etch back. Depending upon the device geometry and process parameters, perhaps from 1 to 10 cycles could be employed—although a greater number of cycles is within the contemplated scope of the invention.

FIG. 1 h illustrates the structure after an appropriate number of cycles have been performed. Oxide regions 7 have been recessed to a desired level. At the same time, damaged regions 12 (see FIG. 1 g) have been either partially or completely removed, leaving fins 10 with more structurally intact surfaces.

An anneal step may also be performed upon completion of the appropriate number of cycles of oxidizing treatment and etch process. One anneal step may be performed or a series of anneal steps could be performed intermediate various cycles. In one embodiment, an H₂ anneal is performed, using a concentration of from about 5% to 100% H₂ in a N₂ carrier at an elevated temperature in the range of from about 600° C. to about 1100° C. Depending upon the device geometry and the anneal parameters, the anneal time could range from 30 seconds to 30 minutes in some embodiments. The anneal step may relax the fin material and improve the surface smoothness of fins 10, as is known in the art.

The etch back process as described above comprises a wet oxidizing treatment followed by a dry etch process and may require two separate chambers, one for a wet process and another for a dry process. In other embodiments, oxidation and etch processes may be performed in a single chamber. For example, each cycle of the etch back process comprising an oxidation process followed by an etch process may be performed in a wet chamber. Using a single chamber for the etch back process may provide advantageous benefits, such as high device throughoutput and low process cost. In some embodiments, the oxidizing treatment is performed using a mixture of HF, ozone (O₃) and deionized (DI) water (FOM). The ozone concentration in the FOM mixture is from about 1 ppm to about 500 ppm, and the HF concentration in the FOM mixture is between about 100 ppm and about 10000 ppm. In some embodiments, the oxidizing treatment is performed for about 30 seconds to about 300 seconds, at a temperature between about 22° C. and about 80° C. It is believed that the top surface of fins 10, including damaged regions 12, are at least partially oxidized during the FOM treatment. In some embodiments, assuming fins 10 are initially formed of GaAs, after the oxidizing treatment, the exposed surface of fins 10 is converted to an oxide of gallium arsenide, such as GaAsO down to a depth of about 5 Å to about 100 Å. One advantageous feature of the oxidizing treatment is that the FOM mixture provides a cleaning treatment to exposed surfaces in addition to the oxidizing treatment.

In a next step of the etch back process, the device is subjected to an etch process. In some embodiments, the etch process is a wet etch process using, for example, a diluted HF (DHF), a solution of HF in DI water with a HF concentration from about 100 ppm to about 10000 ppm. The etch process may be performed at a temperature between about 22° C. and 45° C. for a period of from about 10 seconds to about 60 seconds. This etch process removes top surfaces of oxide regions 7 and hence etches back oxide regions 7 into recesses formed between fins 10. At the same time, this etch process removes portions of fins 10 that have been oxidized during the previous FOM treatment. One skilled in the art will recognize that other etchants could be employed in addition to or in lieu of the above described DHF.

In some embodiments, a single cycle of oxidizing treatment and etch process may be sufficient to etch back oxide regions 7 to a desired height and to remove damaged regions 12. In other embodiments, however, it may be desirable to subject the device to a series of cycles involving an oxidizing treatment followed by an etch process. Depending upon the device geometry and process parameters, number of cycles may vary from 1 to 10 cycles, although a greater number of cycles is within the contemplated scope of the present disclosure.

An anneal step may also be performed upon completion of the appropriate number of cycles of oxidizing treatment and etch process. In other embodiments, a series of anneal steps may be performed between various cycles. In some embodiments, the anneal step is performed in an N₂/H₂ atmosphere as described above and the description is not repeated herein. The anneal step may relax the fin material and improve the surface smoothness of fins 10.

Processing may then continue to form a desired device. For instance, regions of a fin 10 may be doped with an appropriate impurity to form source and drain regions of a MOS transistor. A gate oxide and gate electrode may be formed over a channel region of the fin to complete the MOS device. Because these structures and processes are well known to those skilled in the art, they are not illustrated herein, although the form part of the contemplated embodiments.

One skilled in the art will recognize that the sidewalls of fins 10, once exposed, will also be oxidized during the subsequent oxidizing treatments and etched during the subsequent etch processes. Hence, it may be necessary to adjust the nominal thickness of fins 10 in the design stage to compensate for the slight amount of sidewall etch back that might occur. As an example, the amount of sidewall etch back can be empirically determined or can be modeled and the width of recesses 4 (in which fins 10 are formed) can be adjusted to compensate for the sidewall thinning. Such adjustment can be made as a matter of routine experimentation.

FIGS. 2 a through 2 e illustrate yet further embodiments. Where appropriate like or analogous elements are referenced with a common reference numeral in FIGS. 1 (including 1 a through 1 h) and 2 (including 2 a through 2 e). Beginning with FIG. 2 a, a substrate 2 is illustrated upon which has been formed oxide layer 6. Oxide layer 6 is patterned, using known photolithography and etching techniques for form a series of recesses 14 defining oxide regions 7. Three such recesses are shown in FIG. 2 b, although one skilled in the art will recognize that number, placement, and geometry of recesses 14 are matters of design choice.

As illustrated in FIG. 2 c, fin material 8 is epitaxially grown on substrate 2, filling and overfilling recesses 14. Illustrative methods for growing/depositing fin material 8 have been discussed above with regard to FIG. 1 f and hence are not repeated herein. As with the previously described embodiments, it is necessary to subject fin material 8 to a CMP process in order to thin the material back to be planar with the tops of recesses 14 formed in oxide 6, i.e. to be co-planar with oxide regions 7. The result of this CMP step, as illustrated in FIG. 2 d is the formation of fins 10 having a top surface that is co-planar with oxide 6. An unintended consequence of the CMP process is the formation of damage regions 12 to the tops of fins 10.

As in the previously described embodiment (described with reference to FIGS. 1 a through 1 h), it is necessary to thin back or etch back oxide 6. It is desirable obtain a relatively planar top surface of the resulting thinned back oxide regions 7, as was previously discussed. It is further desirable to reduce or eliminate damaged regions 12 from the top surface of fins 10. These goals are accomplished by subjecting the device illustrated in FIG. 2 d to one or more cycles of the oxidizing treatment and etch back process discussed above. A result of such processing is illustrated in FIG. 2 e, wherein oxide regions 7 are etched back to a desired height and have relatively planar top surfaces. A further result of such processing is that damaged regions 12 of fins 10 have been eliminated or at least substantially reduced.

Processing can then continue, such as in some embodiments, with the formation of source and drain regions in the fins 10, and the formation of gate oxide, gate electrode, etc. over the fins to form complete devices such as MOS transistors, bipolar junction transistors, and the like. FIG. 3 illustrates one such structure, finFET 20. As shown, a finFET transistor 20 can be formed in a fin 10 embedded in oxide regions 7. Source and drain regions 22, 24 are implanted or otherwise formed in fin 10 using techniques known in the art. Gate electrode 26 and gate oxide 28 are formed and patterned over fin 10. The resulting structure 20 provides improved device performance and reliability because of the improved surface characteristics and lessened surface damage to fin 10, as described above.

In an embodiment, a method of forming a semiconductor device, the method comprises forming a patterned dielectric layer on a substrate, the patterned dielectric layer having openings exposing portions of the substrate, forming a first semiconductor material in the openings, a top surface of the first semiconductor material being substantially planar with a top surface of the patterned dielectric layer, and performing one or more process cycles. Each process cycle of the one or more process cycles comprises oxidizing the top surface of the first semiconductor material, thereby forming an oxidized surface on the first semiconductor material, and removing the oxidized surface of the first semiconductor material and a portion of the patterned dielectric layer.

In another embodiment, a method of forming a semiconductor device, the method comprises forming a plurality of parallel strips of a first semiconductor material on a substrate, wherein a plurality of dielectric regions are interposed between neighboring parallel strips, top surfaces of the plurality of parallel strips being substantially planar with top surfaces of the plurality of dielectric regions, performing an oxidizing process, the oxidizing process forming oxide layers on the plurality of parallel strips, and performing an etching process, the etching process etching the oxide layers and the plurality of dielectric regions.

In yet another embodiment, a method of forming a FinFET device, the method comprises forming a fin on a substrate, wherein the fin is interposed between a first dielectric region and a second dielectric region, recessing the first dielectric region and the second dielectric region, thereby exposing a portion of the fin, and simultaneously with recessing the first dielectric region and the second dielectric region, removing a damaged region of the fin.

The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure. 

What is claimed is:
 1. A method of forming a semiconductor device, the method comprising: forming a patterned dielectric layer on a substrate, the patterned dielectric layer having openings exposing portions of the substrate; forming a first semiconductor material in the openings, a top surface of the first semiconductor material being substantially planar with a top surface of the patterned dielectric layer; and performing one or more process cycles, each process cycle comprising: oxidizing the top surface of the first semiconductor material, thereby forming an oxidized surface on the first semiconductor material; and removing the oxidized surface of the first semiconductor material and a portion of the patterned dielectric layer.
 2. The method of claim 1, wherein the forming the patterned dielectric layer comprises: forming a dielectric layer on the substrate; and patterning the dielectric layer, thereby forming the openings in the dielectric layer.
 3. The method of claim 1, wherein the forming the patterned dielectric layer comprises: forming trenches in the substrate; forming a dielectric material layer in the trenches; and removing a portion of the substrate at least partially exposing sidewalls of the patterned dielectric layer.
 4. The method of claim 1, further comprising annealing the semiconductor device in an N₂/H₂ atmosphere, after at least one of the cycles of the one or more process cycles is completed.
 5. The method of claim 1, wherein the oxidizing is performed using a mixture of deionized water (H₂O), ozone (O₃), and hydrofluoric acid (HF).
 6. The method of claim 5, wherein an O₃ concentration is between about 1 ppm and about 500 ppm, and an HF concentration is between about 100 ppm and about 10000 ppm.
 7. The method of claim 1, wherein the removing is performed at least in part by etching using diluted hydrofluoric acid (DHF).
 8. The method of claim 1, wherein a bottom surface of the patterned dielectric layer is lower than an uppermost surface of the substrate.
 9. The method of claim 1, wherein the substrate comprises a second semiconductor material, the second semiconductor material being different from the first semiconductor material.
 10. A method of forming a semiconductor device, the method comprising: forming a plurality of parallel strips of a first semiconductor material on a substrate, wherein a plurality of dielectric regions are interposed between neighboring parallel strips, top surfaces of the plurality of parallel strips being substantially planar with top surfaces of the plurality of dielectric regions; performing an oxidizing process, the oxidizing process forming oxide layers on the plurality of parallel strips; and performing an etching process, the etching process etching the oxide layers and the plurality of dielectric regions.
 11. The method of claim 10, further comprising performing the oxidizing process and the etching process one or more times.
 12. The method of claim 10, wherein the plurality of dielectric regions extend into the substrate.
 13. The method of claim 10, wherein bottom surfaces of the plurality of parallel strips are coplanar with bottom surfaces of the plurality of dielectric regions.
 14. The method of claim 10, wherein the oxidizing process is performed using a mixture of deionized water (H₂O), ozone (O₃), and hydrofluoric acid (HF).
 15. The method of claim 10, wherein the etching process is performed using diluted hydrofluoric acid (DHF).
 16. A method of forming a FinFET device, the method comprising: forming a fin on a substrate, wherein the fin is interposed between a first dielectric region and a second dielectric region; recessing the first dielectric region and the second dielectric region, thereby exposing a portion of the fin; and simultaneously with recessing the first dielectric region and the second dielectric region, removing a damaged region of the fin.
 17. The method of claim 16, wherein the recessing the first dielectric region and the second dielectric region with simultaneously removing the damaged region of the fin comprises one or more process cycles, each process cycle comprising: oxidizing the damaged region of the fin, thereby forming an oxidized portion; and etching the oxidized portion of the damaged region, the first dielectric region, and the second dielectric region.
 18. The method of claim 17, wherein the oxidizing is performed using a mixture of deionized water (H₂O), ozone (O₃), and hydrofluoric acid (HF) at a first temperature between about 22° C. and about 80° C.
 19. The method of claim 17, wherein the etching is performed using diluted hydrofluoric acid (DHF) at a second temperature between about 22° C. and about 45° C.
 20. The method of claim 17, further comprising annealing in an N₂/H₂ atmosphere at a temperature between about 600° C. to about 1100° C. for a period between about 30 seconds to about 30 minutes, after at least one cycle of the one or more process cycles is completed. 